Erosion resistant cermet linings for oil & gas exploration, refining and petrochemical processing applications

a technology of cermet and petrochemical, applied in the field of cermet materials, can solve the problems of protecting the walls of the refinery process vessel, and the internals of the vessel, and the internals of the vessel, and the internals are exposed to aggressive fluids containing hard, and are subject to both erosion and corrosion, and achieve excellent stability, excellent erosion resistance to sand, and outstanding thermal expansion compatibility to various substrate metals.

Inactive Publication Date: 2008-01-03
EXXON RES & ENG CO
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  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0015]Another advantage of the method for protecting metal surfaces with a cermet lining, insert or coating of the present disclosure is that outstanding hardness is exhibited.
[0016]Another advantage of the method for protecting metal surfaces with a cermet lining, insert or coating of the present disclosure is that excellent stability at high temperatures from thermal degradation in the cermet microstructure is exhibited, thus making the method highly desirable and unique for long term service in high temperature refinery and petrochemical process applications.
[0017]Another advantage of the method for protecting metal surfaces with a cermet lining, insert or coating of the present disclosure is that excellent erosion resistance to sand and other abrasive particulars is exhibited, thus making the meth...

Problems solved by technology

For example, refinery process vessel walls and internals exposed to aggressive fluids containing hard, solid particles such as catalyst particles in various chemical and petroleum environments are subject to both erosion and corrosion.
The combined properties of high temperature erosion resistance and toughness are required for linings and inserts used to provide long term erosion/abrasion resistance of internal metal surfaces in refining and petrochemical process units with operating temperatures above 600° F. The protection of these vessels and internals against erosion and corrosion induced material degradation especially at high temperatures is a technological challenge.
The castable alumina refractories have adequate temperature and corrosion resistance, but limited erosion resistance.
The life span of the state-of-the-art refractory liners is significantly limited by excessive mechanical attrition of the liner from the high velocity solid particle impingement, mechanical cracking and spallation.
When these bonds are upgraded with stronger direct bonding of the ceramic grains, the overall lining becomes expensive to fabricate and prone to catastrophic, brittle fracture failures.
Thin layer ceramic coatings or weld overlays of precipitation hardened alloy may also be used for high temperature erosion resistance, but are less effective than conventional chemically bonded, castable refractory linings.
Thickness and ceramic content are constrained in weld overlays and plasma s...

Method used

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  • Erosion resistant cermet linings for oil & gas exploration, refining and petrochemical processing applications
  • Erosion resistant cermet linings for oil & gas exploration, refining and petrochemical processing applications
  • Erosion resistant cermet linings for oil & gas exploration, refining and petrochemical processing applications

Examples

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example 1

Illustrative Example 1

[0078]The TiB2 in stainless steel binder cermet of the present invention was tested experimentally as a liner in an actual cyclone drum or cylinder of an FCCU unit of a refinery. The liner was formed from tiles created by powder metallurgy processing attached via fusion welding of metal anchor to the inside wall of the cyclone. To provide a direct comparison with the prior art materials, sections of the cyclone liner or drum were also provided with Si3N4 tiles, SiC tiles, alumina tiles of 1½″ square and alumina tiles of 4½″ square. The cyclone drum was exposed to 26 thermal cycles with heat / cool rates from. The cyclone drum of FIG. 6 was exposed to 26 thermal cycles with heating / cooling rate severity of up to 500° F. / hr (100° F. / hour to 500° F. / hour) in FCCU catalyst. The prior art Si3N4 and SiC lining tiles (FIG. 6(a)), and the prior art alumina lining tiles (FIG. 6(b) and (c)) all failed as exhibited by cracks in and missing tiles after exposure to 26 thermal...

example 2

Illustrative Example 2

[0079]The HER cermet linings and inserts of the present invention are suitable for many areas in refining and petrochemical processing units with temperatures in excess of 600° F. (316° C.) where FIG. 7 depicts a plot of HEAT determined erosion resistance (HEAT erosion resistance index) versus K1c fracture toughness (MPa-m1 / 2) of a wide range of material candidates for high temperature linings using measured or published fracture toughness data for three point bending at room temperature. The plot exhibits that prior art materials (hard alloys and WC, refractories, and ceramics) follow the trend line showing the inverse relationship between fracture toughness and erosion resistance. That is a material with a high hot erosion resistance has poor fracture toughness and vice-versa. By comparison, data for the HER cermet linings of the present invention do not fall along the trend line, but are within a different regime considerably above the trend line (see “HER c...

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Abstract

The present invention is directed to a method for protecting metal surfaces in oil & gas exploration and production, refinery and petrochemical process applications subject to solid particulate erosion at temperatures of up to 1000° C. The method includes the step of providing the metal surfaces in such applications with a hot erosion resistant cermet lining or insert, wherein the cermet lining or insert includes a) about 30 to about 95 vol % of a ceramic phase, and b) a metal binder phase, wherein the cermet lining or insert has a HEAT erosion resistance index of at least 5.0 and a K1C fracture toughness of at least 7.0 MPa-m 1/2. The metal surfaces may also be provided with a hot erosion resistant cermet coating having a HEAT erosion resistance index of at least 5.0. Advantages provided by the method include, inter alia, outstanding high temperature erosion and corrosion resistance in combination with outstanding fracture toughness, as well as outstanding thermal expansion compatibility to the base metal of process units. The method finds particular application for protecting process vessels, transfer lines and process piping, heat exchangers, cyclones, slide valve gates and guides, feed nozzles, aeration nozzles, thermo wells, valve bodies, internal risers, deflection shields, sand screen, and oil sand mining equipment.

Description

FIELD OF THE INVENTION[0001]The present invention relates to cermet materials. It more particularly relates to the use of cermet materials in fluids and solids process applications requiring erosion resistance. Still more particularly, the present invention relates to the use of hot erosion resistant cermet linings and inserts requiring superior erosion / corrosion resistance, and fracture toughness for use in oil & gas exploration and production, refining and petrochemical processing applications.BACKGROUND OF THE INVENTION[0002]Erosion resistant materials find use in many applications wherein surfaces are subject to eroding forces. For example, refinery process vessel walls and internals exposed to aggressive fluids containing hard, solid particles such as catalyst particles in various chemical and petroleum environments are subject to both erosion and corrosion. The combined properties of high temperature erosion resistance and toughness are required for linings and inserts used to...

Claims

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Application Information

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IPC IPC(8): B22F7/00
CPCC22C29/04C22C29/12Y10T29/49826C22C29/16C22C29/14
Inventor PETERSON, JOHN R.BANGARU, NARASIMHA-RAO V.ANTRAM, ROBERT LEEFOWLER, CHRISTOPHER JOHNTHIRUMALAI, NEERAJ S.CHUN, CHANGMINLENDVAI-LINTNER, EMERY B.
Owner EXXON RES & ENG CO
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